In the midst of the US Department of Defense’s race to achieve “drone dominance,” an ambitious plan that envisions the acquisition of up to 300,000 single-use attack drones by 2028, the Marine Corps has taken an initial step. This involves the development of its first 3D-printed drone that is fully compliant with the National Defense Authorization Act (NDAA).
The National Defense Authorization Act (NDAA) is the legislation that regulates, among other things, which technologies and components can be used in US military systems, especially in sensitive areas such as communications, electronics, and software. In other words, the NDAA seeks to prevent the use of components with potential backdoors or technological dependencies on countries considered adversaries. The drone, dubbed HANX, is the result of the work of a small team of Marines in North Carolina. Leading the project is Sergeant Henry David Volpe, a motor transport mechanic who has been self-taught in 3D printing and robotics since his teens.
Although the Marine Corps had already experimented with 3D-printed drones in the past, HANX represents a breakthrough for them. Unlike others, the new drone strictly complies with NDAA requirements, which means that all its components are free of potentially compromised hardware and software. HANX has been designed as a modular platform that Marines themselves can print, modify, and repair. This allows the design to be quickly adjusted for different missions. Intended uses include tactical reconnaissance, light logistics, training, and even as a low-cost attack drone.
In just 90 days, Sergeant Volpe developed five major versions of the drone and dozens of minor iterations. To ensure that motors, controllers, sensors, and communication systems met NDAA standards, Volpe spent several months researching, contacting manufacturers directly, and obtaining validation from government agencies, including NAVAIR, which is responsible for flight certification. Finally, HANX obtained interim flight approval, becoming the Marine Corps’ first 3D-printed drone with official authorization to operate. Following approval, the Innovation Campus began transforming the project into a training program, with training plans and course frameworks so that other units could manufacture and maintain their own drones. Some units, such as special forces and explosive ordnance disposal teams, have already shown immediate interest in producing more HANX units for specific missions, according to a Marine Corps statement.
The rapid evolution of drones and the current international context are causing debate and uncertainty; there is no doubt about that. However, understanding how these technologies are integrated into military structures is key to analyzing the role that additive manufacturing will play in the future.
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*All Photo Credits: MARINE CORPS / Sgt. Alfonso Livrieri